Composite self-drilling soil nail and method

ABSTRACT

A subsurface support comprises a soil nail having an outer member and an inner member placed within the outer member. Features are provided to maintain a uniform spaced relationship between the inner and outer members. The spaced relationship may be achieved by crimping the outer member, or by use of an insert installed between the inner and outer members. In another embodiment, the support is made of composite construction materials, and having a self-drilling capability. The outer member may be fiberglass, and a metallic drill bit may be secured to a distal end of the soil nail. The inner member is preferably steel. A method is also provided to improve pull-out capacity by galvanizing the inner and outer members.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of co-pendingU.S. application Ser. No. 11/693,584, filed on Mar. 29, 2007 entitled“METHOD AND APPARATUS FOR CREATING SOIL OR ROCK SUBSURFACE SUPPORT”,which is a continuation-in-part application of co-pending U.S.application Ser. No. 11/460,317, filed on Jul. 27, 2006, entitled“METHOD AND APPARATUS FOR CREATING SOIL OR ROCK SUBSURFACE SUPPORT”,which is a continuation-in-part of co-pending U.S. application Ser. No.10/741,951, filed on Dec. 18, 2003, entitled “METHOD AND APPARATUS FORCREATING SOIL OR ROCK SUBSURFACE SUPPORT”, the disclosures of theseapplications being hereby incorporated by reference herein in theirentirety.

FIELD OF THE INVENTION

The present invention relates generally to subsurface supports placed inthe ground, and more particularly, to a method and apparatus forcreating soil or rock subsurface supports that can be used in multipleapplications to include support for excavations as a passive soil nailin tension, bending and/or shear, support to stabilize sloping terrainas a tieback in tension, support for an above ground structure as amicropile in compression and/or shear, or support for an above groundstructure as an anchor in tension. A preferred embodiment of theinvention includes a composite self-drilling soil nail installed bydrilling.

BACKGROUND OF THE INVENTION

In the construction of buildings, bridges, and other man-madestructures, it is well known to place passive supports such as footers,piles, and other subsurface supports for supporting such man-madestructures. These types of supports are passive because the earth aroundthe subsurface support must first shift or move to mobilize theavailable tensile, bending, or shear capacities.

One particular problem associated with subsurface supports which may bemade of iron, steel, or other metals is that over time, corrosion takesplace which ultimately degrades the ability of the support to providedesigned support for an overlying structure.

In addition to providing the above-mentioned subsurface supports, it isalso known to provide ground strengthening by driving elongatereinforcing members, referred to as soil nails, into the ground in anarray thus improving the bulk properties of the ground. The soil nailsthemselves are not used for direct support of an overlying structure;rather, the soil nails are simply used to prevent shifting or otherundesirable properties or characteristics of a particular geologicalformation that is built upon.

In some cases, the earth surrounding or near a man made structurebecomes unstable and requires active support, such as by a tieback.Tiebacks are pre-tensioned subsurface supports that are used to restrainany movement of surrounding soil and rock. Tiebacks are similar topassive soil nails in construction, and can be emplaced in a similarfashion as a soil nail. More recently, soil nails and tiebacks have alsobeen used to provide temporary and permanent excavation support andslope stabilization.

The U.S. Pat. No. 5,044,831 discloses a method of soil nailing wherein asoil nail is placed in the ground by being fired from a barrel of alauncher. The soil nail is loaded into the barrel, and pressurized gasemitted from the barrel forces the soil nail into the ground to adesired depth. One advantage of using a soil nail launcher is that thesoil nails can be emplaced with a minimum amount of labor and equipmentthereby minimizing environmental impacts as well as providing a simpleand economical means of strengthening the ground. Drilling is thetraditional way to install soil nails, tiebacks, and anchors.

Although there are a multitude of subsurface supports and methods bywhich subsurface supports can be emplaced, there is still a need forsimple and effective subsurface supports and an environmentally friendlymanner in which subsurface supports are emplaced.

SUMMARY OF THE INVENTION

In accordance with the present invention, a method and apparatus areprovided to create a subsurface support device that is placed in theground. In a first embodiment of the invention, the support device ofthe present invention has many potential uses. In one use, this supportdevice can be used as a passive soil nail. In another use, this supportdevice of the present invention can be used as an active tieback intension. More generally, for use as a tieback, this support device canalso be referred to as a soil or rock inclusion. The term inclusionrefers to the ability of the support device to increase the tensilecapacity of the rock and soil. In yet another use, this support devicecan be used as a micropile in compression, bending and shear. Thissupport device, when acting as a micropile, can be physically connectedto an overlying structure. In yet another use, this support device canbe used as an anchor in tension. For example, this support may betensioned as by a cable that interconnects the support to a man madestructure.

Once emplaced, this support device includes a protective outer member ortube, an inner support member, and a stabilizing mixture, preferably inthe form of grout, cement, resin, or combinations thereof which fixesthe inner support member within the outer protective member. Thestabilizing mixture may also be referred to as a cementious mixture. Theouter protective member supports the opening into the native rock andsoil, and acts as a housing for the cement us mixture. As discussedfurther below, the outer member may be perforated thereby allowing thecement us material to exit the perforations and increase the overalltensile and compressive contribution of the support device. The outerprotective member also provides a barrier to prevent water or othercorrosive materials from contacting the inner support member. The innersupport member provides the design tensile and compressive strength ofthe support. The inner support member may protrude a desired distanceabove the outer member to connect to an overlying structure to providesupport in any desired manner to include bearing/compression, tension,and/or shear. The diameter and length of the outer member and innermember can be selected to provide the necessary support. The outermember and stabilizing mixture provide strengthening support to theinner member. For example, in compression, the forces are transmittedfrom the inner support member directly to the stabilizing mixture andthe outer member. In tension, forces are also transmitted to thestabilizing mixture and the outer member thereby greatly increasing theforce necessary to dislodge or pull out the inner member. The method bywhich the outer member of the subsurface support is emplaced in theground is preferably by a launching mechanism, such as that disclosed inthe U.S. Pat. No. 5,044,831.

In another embodiment of the present invention, the support device is inthe form of an improved soil nail including a fiberglass body and ametal tip. The metal tip is preferably made from a single piece ofmetal, such as a machined ingot of hardened steel. The tip comprises acontacting portion or stinger that makes contact with the ground whenemplaced, and a proximal base portion that is received within an openingin the distal end of the fiberglass body thus allowing the tip to beattached to the fiberglass body. The base portion may be attached by acompression fit within the opening of the body and/or may be secured byan appropriate bonding agent, such urethane glue. The size anddimensions of the soil nail can be modified for the intended purpose ofuse. One common size acceptable for use in many soil stabilizationefforts includes a fiberglass body of twenty feet in length and acontacting portion of the metal tip extending approximately six inchesin length from the distal end of the fiberglass body. For thoseapplications in which a shorter body is required, the same tipconstruction can be used, and the length of the body can simply beshortened. Unlike most prior art soil nails, the soil nail of thepresent invention has a tubular shaped body without projections whichallows the soil nail to be emplaced by the soil nail launcher disclosedin the U.S. Pat. No. 5,044,831. The use of a soil nail with a fiberglassbody in conjunction with a metal tip provides many advantages. Thefiberglass body provides a more cost effective solution than traditionalsoil nails that are just made of metal. The fiberglass body also ishighly resistant to corrosion, even more so than many metal soil nailswithin corrosion treated surfaces. The weight of the soil nail of thepresent invention is also less than a metal soil nail, allowing it toachieve greater velocity when emplaced by a soil nail launcher, thusenhancing its ability to penetrate the ground. The strength of the soilnail is not compromised because the fiberglass has adequate strength,and has a greater elastic limit as compared to many metal soil nailsenabling the nail to handle even greater tensile and shear loads.Although the soil nail has a relatively smooth outer surface allowing itto be emplaced by a launcher, the surface characteristics of thefiberglass provide excellent adhesion with soil. Additionally, thestinger can be especially designed to handle particular soil or rockformations without having to modify the body of the soil nail. Forexample, in more dense soil or rock formations, the stinger shape can bemodified prior to assembly with the body thus making the soil nail moreadaptable for many uses.

In another preferred embodiment of the present invention, aself-centralizing soil nail is provided. This self-centralizing featureenables the inner member or inner bar to be centralized within the outermember. The inner member maintains a uniform concentric relationshipwherein the inner member is uniformly spaced from the inner surface ofthe outer member. This feature is achieved by crimping the outer memberat selected locations along the length of the outer member therebynarrowing the inner diameter of the outer member, but maintaining anopening in the outer member large enough for passage of the innermember. The outer member is crimped so that the inner member is centeredin the opening of the outer member and, the space between the outersurface of the inner member and the interior surface of the outer memberis substantially uniform. Placing the inner member in this centralizedrelationship increases the capacity of the soil nail both in tension andcompression. If the soil nail is not centered and makes contact with theinterior surface of the outer member, the inner member is subject tocorrosion. Additionally, if the inner member is spaced too closely tothe interior surface of the outer member, there may be small voids orspaces that do not completely fill with cementious material and/or thecementious may have a very small thickness which is more susceptible tobeing fractured. The narrowing of the diameter of the outer memberachieves natural centering of the inner member without having to make anouter member of a more complex construction.

In yet another embodiment of the present invention, this self-centeringfeature can be achieved by use of one or more self-centralizing elementsthat may be installed within the outer member. These self-centralizingelements may be in the form of inserts or spacers that have an outerdiameter sized to frictionally engage the inner diameter of the outermember. The centralizing element has an inner diameter that is sized tofrictionally receive the inner member thereby holding the inner member.The centralizing elements may be located at the proximal and distal endsof the outer member, with one or more centralizing elements also beingplaced intermediate between the proximate and distal ends.

In yet another embodiment, the self-centralizing feature of the presentinvention may be incorporated into a soil nail that is installed bydrilling the soil nail into the ground. This self-drilling soil nailincludes a drilling bit secured to the distal end of the soil nail.

In yet another preferred embodiment of the present invention, acomposite self-drilling soil nail is provided in which the soil nail isinstalled by drilling. The soil nail is self-installing by inclusion ofa drill tip attached to the distal end thereof. This soil nail morespecifically comprises an outer member or tubular member having athreaded outer surface with a hollow opening or bore extendingtherethrough, and the hollow bore also being threaded. Preferably, theouter member is made of a material such as fiberglass. If it isnecessary to extend a length of the outer member, an outer coupler maybe used to join the distal end of one outer member with proximal end ofan abutting outer member. The outer coupler is a tubular member itself,having internal threads which are threaded in an engagement with theabutting ends of the outer members. A threaded inner member is placedthrough the threaded bore of the outer tubular member by threadedengagement between threads on the inner bore and external threads on theouter surface of the inner member. As mentioned, the drill tip issecured to the most distal end of the soil nail enabling the soil nailto be self-drilled. The proximal end of the soil nail receives a bearingplate sized to hold or bear against the specific geological formationbeing held by the soil nail. An outer nut is threaded over the outermember and in engagement against the bearing plate. An inner nut isthreaded over the inner member that has an end protruding beyond theadjacent end of the outer member, and the inner nut is tightened againstthe outer nut. The use of the threaded inner member enhances thestrength of the soil nail, particularly when using fiberglass as theouter member, and also when fiberglass sections are to be joined forextending a length of the soil nail. The use of steel couplers improvesthe strength of the joint between the outer members; however, metalliccouplers will corrode over time. The use of the inner member providesmore permanent tensile and compressive capacity to the overall soilnail, and also helps to compensate for weakening of the metallic couplerover time. If fiberglass couplers are used, the joint between the outertubular members is relatively weak, but the inner bar again greatlyenhances the bearing capacity of the soil nail. The use of two holdingnuts as opposed to a single nut against the bearing plate furtherprovides strength to the system.

The primary problem with use of fiberglass is that fiberglass has a verylow shear resistance. Therefore, creating threads on a fiberglass memberwill result in a very weak connection at that threaded location, whichclearly limits the application of fiberglass soil nails when they mustbe threaded. One solution provided by the present invention is the useof the inner member which overcomes any deficiencies with respect to athreaded fiberglass member.

In another aspect of the invention, various embodiments are providedwith surface irregularities or asperities that increase the pull-outcapacity of the soil nail. In one embodiment, the surface asperitiesinclude protrusions formed on the outer surface of the soil nail. Inanother embodiment, the surface asperities may include indentations.These surface asperities may be used in combinations. In another aspect,the surface asperities are created by a galvanization process in whichthe outer tube or member is subjected to a hot dip galvanizing process.The molten metal that is to be applied to the outer member is stirred inorder to suspend particles in the molten metal. These particles arereferred to as dross. More specifically, dross is the mass of solidimpurities that may float on the surface of the molten metal, or may bea heavier impurity that can sink to the bottom of the container holdingthe molten material. These impurities are usually removed by skimmingthe surface or screening the molten material before the object issubjected to the hot dip galvanization. In the present invention, thesestirred particles within the molten metal provide a beneficial purposein the creation of a very rough layer of material applied to the outermember. This roughness increases the pull-out capacity, as well as toprovide an increased capability for the tube to bond to cementiousmaterial placed within the outer member. Therefore, the particles thatare normally skimmed from the surface of the molten metal provide a veryuseful purpose with respect to treating the surface of the outermembers.

In yet another embodiment of the present invention, a system is providedfor repairing a roadway in which cracking and deterioration of theroadway is caused by a slip plane in the roadbed. The system includes aplurality of soil nails that extend through the slip plane and thereforejoin the earth on the opposing sides of the slip plane to stabilize thesurrounding area. In this configuration, the soil nails are installed atvarious angles to extend substantially perpendicular to the slip plane.The soil nails each include a protective outer member or tube, an innersupport member, and a stabilizing mixture preferably in the form ofgrout, cement, resin, or combinations thereof. The upper ends of thesoil nails terminate below the paved surface of the road. A wire meshlayer is placed over the upper ends of the soil nails and coverspreferably a significant portion of the earth lying above the slipplane. The mesh is then held in place by galvanized plates which arefitted over the protruding upper ends of the inner support members. Thegalvanized plates are then secured to the inner members by, for example,epoxy-coated nuts.

Other features and advantages of the present invention will becomeapparent by a review of the following figures, taken in conjunction withthe detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-section of the subsurface support of the presentinvention in a first embodiment, the support device being emplaced inthe ground and providing tensioning support to an overlying above groundstructure;

FIG. 2 is a cross-section illustrating an example launcher that may beused to emplace the outer member of the support device;

FIG. 3 is a partial cross-section illustrating a second embodiment ofthe support device emplaced in the ground and providing compression orbearing support to an overlying structure;

FIG. 3A is an enlarged section of FIG. 3 illustrating one way in whichto provide holes or perforations in the subsurface support;

FIG. 4 is a simplified elevation of a plurality of support devices thatmay be used as passive soil nails or as tiebacks to stabilize a slopingsurface, the supports being emplaced in a horizontal orientation;

FIG. 5 is an exploded fragmentary perspective view of a third embodimentof the present invention in the form of an improved soil nail;

FIG. 6 is a fragmentary side view of the soil nail of FIG. 5;

FIG. 7 is a cross section similar to FIG. 2 illustrating the soil of thethird embodiment being loaded in the launcher;

FIG. 8 shows an example installation of the soil nail of the thirdembodiment to reinforce soil near a river or streambed against scouring.

FIG. 9 illustrates yet another embodiment of a subsurface support of thepresent invention in the form of a soil nail;

FIG. 10 is a cross-section taken along line 10-10 of FIG. 9;

FIG. 11 is a perspective view of a modification of the embodiment ofFIG. 9;

FIG. 12 is a perspective view of yet a further modification of theembodiment of FIG. 9; and

FIG. 13 is a schematic diagram illustrating a method of manufacturingthe embodiment of FIG. 9;

FIG. 14 is a perspective view of yet another embodiment of the presentinvention showing a soil nail with protruding asperities;

FIG. 15 is a perspective view of another embodiment of the subsurfacesupport of the present invention;

FIG. 16 is a perspective view of the embodiment of FIG. 15 includingadditional crimps along the middle of the support;

FIG. 17 is a cross sectional view taken along line 17-17 of FIG. 15;

FIG. 18 is a perspective view of another embodiment including two outermembers interconnected by a coupler thereby extending the length of thesupport; and

FIG. 19 is a perspective view of another embodiment of the presentinvention in which the centering feature includes an insert or spacer;

FIG. 20 is a side view of another embodiment of the subsurface supportincluding a composite construction of steel and fiberglass materials;

FIG. 21 is a schematic view of a roadway repair along a slip plane usinga plurality of subsurface supports; and

FIG. 22 is an elevation view showing further details of a soil nail ofFIG. 21 when installed to repair the roadway.

DETAILED DESCRIPTION

Referring to FIG. 1, the subsurface support 10 in a first embodiment ofthe present invention is shown installed in the ground G. The supportdevice includes an outer member; preferably in the form of a steel oriron tube 12 having a selected length and diameter, and having anintegral pointed tip 14. The tip 14 can be conical in shape thatfacilitates emplacement of the outer tube as by a launcher, as discussedbelow. After the outer tube is emplaced, the stabilizing mixture isplaced in the interior chamber of the outer tube. Then, an inner supportmember that can be in the form of an epoxy coated steel rod or bar isthen placed within the stabilizing mixture prior to hardening of themixture. When the stabilizing mixture cures, the inner support member 16can provide support to an overlying structure in compression, tension,and/or shear. Depending upon the design requirements of the particularstructure to be built, a plurality of subsurface supports may beemplaced at desired locations at the construction site, and each of thesupport devices can be sized to provide the necessary support.

FIG. 1 also illustrates one example of the manner in which the supportdevice 10 provides support. This one example illustrates use of thesubsurface support as an anchor in tension. The subsurface support 10includes a head or cap 20 that is connected to the exposed upper end ofthe inner support member 16. This head or cap can be attached by anintegral threaded member 21 that is placed into a threaded well formedin the upper end of the inner support member 16. The cap or head 20 thencan be used for attachment to the overlying structure. In the example ofFIG. 1, a ring 22 attaches to the cap 20, and a cable 24 connects to theabove ground structure (not shown). Thus, in FIG. 1, the support deviceis used for providing tensioning support to the manmade structure. Ifthe device 10 was needed to provide support in compression, the innersupport member 16 could be directly connected to the foundation or otherbase support of the overlying manmade structure, as further discussedbelow with respect to FIG. 3.

Referring now to FIG. 2, a launching device 40 is shown as a preferredmethod in which to emplace the outer member of the device 10. Thelauncher 40 illustrated in FIG. 2 corresponds to the launcherillustrated in the U.S. Pat. No. 5,044,831, this reference beingincorporated herein in its entirety. The launcher 40 is shown in itsloaded condition with an outer member/tube 12 loaded in the launcher andready for firing. The outer tube 12 with the pointed end 14 is capableof penetrating the ground upon sufficient impact force. The launcher 40comprises a barrel 42 communicating with a breach 44. The breach 44defines an upper chamber 45. The distal or forward end of the outer tube12 is received within an annular shaped sabot 46, preferably made of aplastics material, which is slidably received within the barrel 42adjacent the chamber 45. The trailing or proximal end of the outer tube12 extends through the chamber 44 and projects rearwards from thelauncher 40 through an aperture formed in the cap or upper surface 50 ofthe breach 44. An annual shaped breach seal 52 seals the outer tube 12with respect to the upper surface 50. A gas inlet tube 54 communicateswith the chamber 45 for the admission of compressed gas. A baffle 56 ofa larger diameter than the barrel 40 forms an axial projection of thebarrel extending into contact with the surface of the ground G. Onfiring the launcher, compressed gas is forced into the chamber 45 thatcauses outer tube 12 to be fired into the ground. The baffle 56 includesa locating ring 58 that forms a snug fit around the sabot 46 such thatthe launcher remains in alignment with the outer tube that is emplacedin the ground. Accordingly, the outer tube when emplaced remains incoaxial alignment with the barrel 42. As also shown in FIG. 2, thebreach seal 52 and sabot 46 may be held in position prior to firing by aplurality of resilient members 60 which exert a separating force betweenthe seal and the sabot.

Although a launcher of a particular construction is illustrated in FIG.2, it shall be understood that other launcher types and methods can beused to emplace the outer tube within the ground. For example, alauncher that makes use of an explosive charge may be used.Alternatively, a vibratory means may also be used along with some forcethat helps to ease the outer tube into the ground. As stated above, itis preferable to avoid excavation for emplacement of the outer tube assuch excavation is equipment and manpower intensive, and environmentallyunfriendly.

FIG. 3 illustrates a second embodiment 10′ of the present invention. Thesupport device 10′ is the same as shown with respect to the subsurfacesupport of the first embodiment, with the exception of a plurality ofperforations/openings 30 which may be formed in the outer tube 12. FIG.3 also illustrates the device 10′ used to support an overlying structureS in compression. More specifically, the device 10′ has its upper end 28embedded within a concrete foundation F of a structure S. The foundationis shown as extending a distance below ground level G. As also shown inFIG. 3, the plurality of perforations/openings 30 which may be formed inthe outer tube allow the stabilizing material 18 to flow out from theopenings 30, thus forming external stabilizing structures 32. Incompression or tension, these external stabilizing features 32 help tostrengthen the connection of the device 10′ to the surrounding soil.When filling the interior chamber of the outer tube with the stabilizingmixture 18, such filling may take place under pressure so that a desiredquantity of the stabilizing mixture 18 exits the perforation/openings30, thereby forming the external stabilizing features 32. In order tocompletely fill the interior chamber of the outer tube, it may bepreferable to commence filling of the chamber from the lower mostportion of the chamber. A line (not shown) carrying the stabilizingmixture under pressure can be inserted in the chamber and extend to thelower most end of the support device, and then as the stabilizingmixture fills the chamber, the line may be raised as necessary. Thoseskilled in the art can envision other ways in which the stabilizingmixture can fill the chamber of the outer tube.

Now referring to FIG. 3A, an enlarged section of the support device 10′is shown specifically illustrating one manner in which holes orperforations may be made in the outer tube 12. In FIG. 3A, the openings30 are formed by creating moon shaped cutouts thereby leaving a chad ortab 34. The chad or tab 34 would be pushed away from the exteriorsurface of the outer tube 12 as the pressurized stabilizing mixtureexited the interior chamber of the outer tube. Alternatively, holescould be drilled or punched in the outer tube 12 in order to create anopening by which the stabilizing mixture could flow through. Thoseskilled in the art can envision other ways in which openings may beformed through the outer tube 12 in order to facilitate flow ofstabilizing mixture therethrough to create the external stabilizingfeatures 32.

FIG. 4 illustrates use of the subsurface support of the invention tostabilize a sloping surface. In the figure, three support devices 10 areillustrated and are spaced from one another in a desired arrangement tobest support the sloping surface. The support devices are disposed in ahorizontal orientation, but it shall be understood that the supportdevices may be placed at any angle or orientation depending upon thesurrounding terrain. The support devices in FIG. 4 would berepresentative of use of the supports as either passive soil nails ortiebacks.

Additionally, the subsurface support of the present invention can beused in combination at a particular jobsite to support an overlyingstructure and to stabilize surrounding soil. In this case, one or moresupport devices can be structurally connected to an overlying structuresuch as shown in the figures, and one or more additional support devicescan be used as soil nails to stabilize the surrounding soil or rockformation. Even in tunnel construction, the support device of thepresent invention can be used to stabilize the soil or rock formationsurrounding the tunnel. In a tunnel, a support device can be emplaced inany orientation to include stabilizing the ceiling/upper surface of thetunnel.

FIGS. 5 and 6 illustrate yet another preferred embodiment of the presentinvention, namely, an improved soil nail 70 of dual materialconstruction. As shown, the nail 70 includes a contacting portion orstinger 72 that attaches to a fiberglass body 74. The soil nail extendssymmetrically along a longitudinal axis A-A. The stinger 72 comprises aconical distal tip 76, and a plurality of axially aligned flanges 78that extend proximally from the tip 76. Spaced between the flanges 78are neck sections 80 defining portions of the stinger with smallerdiameters. A transition flange 82 interconnects the most proximallylocated neck section 80 to an intermediate extension 84. A shoulder 86defines the interface with the distal end of the body 74. A base portion88 extends from the shoulder 86, and is inserted within the opening 90formed in the distal end of the body 74. Preferably, the distal end 92of the body 74 has a flat surface thus providing a complementary flatmating surface with the contacting face 94 of the shoulder 86. As shown,the stinger components are generally smaller in diameter than thediameter of the body 74. Further, the flanges 78 generally have asimilar diameter as compared to the large end of the conical distal tip76. The conical tip 76 and flanges 78 may further include peripheraledges 79 that extend generally parallel to the longitudinal axis A-A ofthe soil nail. The base portion 88 preferably extends approximately onefoot within the opening 90 if the exposed part of the stinger has alength of approximately six inches. If a longer stinger is used, thenpreferably the base portion extends further into the opening 90 in orderto provide adequate support. The base portion may be secured by acompression fitting in opening 90 and/or an appropriate bonding agentcan be used.

Referring to FIG. 7, the soil nail 70 is shown as mounted within thesoil nail launcher 40 of FIG. 2. The soil nail 70 is emplaced in thesame manner as the outer tube 12 described in the first embodiment;however, it being understood that the soil nail 70 is a subsurfacesupport that can also be completely buried within the soil withoutexposing an upper end thereof.

FIG. 8 shows an example use of the soil nails 70. This figurespecifically shows a number of soil nails 70 installed in and around thebed of a body of water, such as a stream or river R to thereby stabilizethe soil around the bed. The soil nails 70 have been placed adjacentsome abutments A that may be used to stabilize an overhead structuresuch as a bridge (not shown). Scouring and other types of erosion can beremedied with use of soil nails in this manner. It shall be understoodthat the soil nail of the present invention can be used in many otherapplications, and FIG. 8 is simply one example.

FIG. 9 illustrates yet another soil nail embodiment of the presentinvention. The soil nail 100 of FIG. 9 includes a plurality of surfaceasperities that improve the pull out capacity of the soil nail. Once asoil nail is in place, it is advantageous for the soil nail to remain inplace without slippage or pull out. With respect to the embodiment shownin FIG. 3, pull out capacity is improved after the cementious materialexits the location of the external stabilizing features. However, thereis also a need to provide a soil nail with improved pull out capacitywherein such features are not activated in a later processing step, butrather, are formed integrally with the soil nail prior to placement. Inthe embodiment of FIG. 9, the body 102 of the soil nail 100 includes aplurality of dimples or indentations 110 formed in a linear pattern.Referring also to FIG. 10, these indentations 110 preferably do not passthrough the entire thickness of the wall of the soil nail therebymaintaining better structural integrity of the soil nail whereas aplurality of holes made in the same linear fashion might otherwisedecrease the overall strength of the soil nail such that it may breakapart upon being fired from a launcher into the ground, or mayprematurely deteriorate in the soil. The surface asperities caused bythe indentations enhance the pullout capacity of the soil nail withoutmaterially weakening the construction of the soil nail. FIG. 9 alsoillustrates an optional stinger 104 attached to the distal end 106 ofthe soil nail. Therefore, as discussed above with respect to theembodiment shown in FIGS. 5 and 6, the stinger may be used to furtherimprove the pullout capacity of the soil nail.

Although the indentations 110 are shown as extending uninterruptedbetween the proximal end 108 and the distal end 106, it is alsocontemplated that the indentations could be provided in a discontinuouspattern, a continuous pattern, or combinations thereof. Additionally,while the indentations are shown as being provided in a linearorientation, it is also contemplated that the indentations could beprovided in a non-linear or random fashion.

FIG. 11 illustrates a modification to the embodiment of FIG. 9 wherein acombination of surface asperities or features are provided to improvethe pull out capacity of the soil nail. In FIG. 11, the soil nail 120has at least one linear set of indentations 124, as well as beingdeformed along a linear line L following the path of the indentations124. The deformed shape of the bar, as well as the indentations eachimproves the pull out capacity of the soil nail.

FIG. 12 shows yet another modification to the embodiment of FIG. 9. Thissoil nail is also deformed along a linear line following a path of theindentations 124, but further includes a plurality of threaded portions126 spaced along the length of the soil nail. The threads also increasethe pull out capacity of the soil nail, and are features that can beformed prior to a placement of the soil nail.

FIG. 13 illustrates a method by which a linear set of indentations maybe formed on opposite sides of the soil nail 100 in accordance with theembodiment of FIG. 9. As shown, an upper sprocket 112 has a plurality ofteeth 114 formed on the outer surface thereof, similar to a sprocket fora bicycle. A lower sprocket 116 with teeth 118 are also provided, anddisposed on an opposite side of the soil nail. In order to form theindentations, the bar is orientated so that it passes between thesprockets, and the sprockets then rotate about their respective centralaxes to form the indentations on the outer surface of the soil nail.

With respect to a method of making the soil nail shown in FIG. 12, afirst step may include creating the various sets of threads 126 on theouter surface of the soil nail. In the next step, the indentations 124can be formed in the manner shown in FIG. 13. Additionally, it iscontemplated that the amount of force or pressure provided by one orboth of the sprockets 112 and 116 could be increased such that the bodyof the soil nail is deformed along the path of the indentations.

FIG. 14 illustrates yet another embodiment of the present invention. Inthis embodiment, the soil nail 130 has a plurality of small asperitiesformed on the outer surface of the nail. The asperities in thispreferred embodiment are shown as small protrusions 132. The protrusionsare relatively small in comparison to the tabs 34 shown in theembodiment of FIG. 3A. The protrusions 132 help in increasing thepullout capacity of the soil nail. One method to create the protrusions132 is to weld small pieces of material to the soil nail. Theprotrusions 132 can be used with a soil nail that is launched fromlauncher 40 without concern that the protrusions will create excessiveinterference which otherwise might deform or break the nail upon beinglaunched. The protrusions can be provided in a geometrically spacedpattern or randomly on the outer surface of the soil nail. Oneacceptable general size for the protrusions may include those thatprotrude approximately one-eighth to one-half inch away from the outersurface of the soil nail. Spacing between each of the protrusions may beapproximately 4-6 inches.

It is also contemplated that the protrusions 132 could also be combinedwith the other asperities shown in FIGS. 9-12. Thus, a composite groupof asperities could be provided on a soil nail to optimize pull outcapacity. A desired combination of the asperities can be tailored tomatch optimum pullout capacity based on the type of soil and rockformations present.

With respect to launching the soil nails illustrated in FIGS. 9-12 and14, the launcher 40 illustrated in FIG. 2 can be used without requiringmodification.

Referring now to FIGS. 15 and 16, in another embodiment of the presentinvention, a subsurface support 200 is illustrated. In this embodiment,the support 200 includes an outer member or tube 202 and an innermember, such as a length of rebar 204 that is placed within the outermember 202. The outer member 202 has a plurality of locations at whichthe hollowed bore or opening 205 of the outer member 202 is made smallerby crimping the outer member. In FIG. 15, there are two crimpedlocations, namely, one crimped area 208 at the distal end 206 of theouter member, and another crimped area 212 located at the proximal end210 of the outer member 202.

In FIG. 16, there are three additional crimped areas 214 located betweenthe proximal and distal ends of the outer tube 202. Depending upon thelength of the outer member, it may be advantageous to provide one ormore intermediate crimped areas which ensure the inner member maintainsa uniform concentric spaced relationship with respect to the outermember.

Referring to FIG. 17, this cross-section illustrates the outer member202 being crimped. As shown, the outer tube maintains its normaldiameter or shape at spaced locations along the outer periphery of theouter tube; while a plurality of crimped sections 228 make the openingor bore 205 smaller at that location.

Referring to FIG. 18, another configuration is shown with respect to thesubsurface support 200 in which the length of the support is extended byuse of two outer members interconnected by a coupler. A proximal end ofa first outer member is attached to a distal end of an adjacent orabutting outer member and these members are connected to one another bya threaded coupler 220. One way in which the coupler 220 may connect theabutting ends of the outer members is by a threaded connection in whichthe outer peripheral surfaces of the abutting ends may have an externalthread, and the coupler may have an internal thread. As also shown, theinner member 204 extends continuously through the bores of both of theouter members 202. This figure also illustrates the use of aself-drilling bit 226 that can be used for emplacement of the subsurfacesupport in which the subsurface support is drilled into the ground andthe self-drilling bit 226 remains within the ground when the subsurfacesupport is drilled to a desired depth.

With respect to installation of the subsurface support 200, there are anumber of methods by which these subsurface supports can be emplaced.One contemplated method is to launch the subsurface support 200 in whichthere is a single outer member 202. The distal end, since it is crimped,has a smaller cross-sectional area that enhances its ability to belaunched into the ground without requiring a separate tip piece. Inorder that the opening at the distal end does not become clogged withsoil or rock, a removable cap (not shown) can be placed over theopening. Alternatively, a hole may be drilled, and the outer member isplaced in the hole. As mentioned, the support 200 may also have a selfdrilling capability in which the support is attached to a drilling tooland the self-drilling bit 226 facilitates drilling.

Once the outer member is emplaced, it is filled with cementious materialby use of, for example, a pressurized grout tube placed within theopening 205. After filling the opening 205, the inner member 204 isinserted through the opening 205 and through the length of the outermember. As shown in the figures, the distal end of the inner member 216may protrude beyond the distal end 206 of the outer member. Similarly,the proximal end 218 of the inner member 202 may extend beyond theproximal end of 210 of the outer member 202. As shown in thecross-section of FIG. 17, the inner bar or member 204 maintains auniform spacing between the outer surface of the inner member and theinterior surface of the outer member. By maintaining the spacedrelationship between the inner and the outer member, the inner memberdoes not rest against or otherwise lie in a position that is too closeto the inner surface of the outer member. Accordingly, the grout willfill the space between the inner and outer members to provide additionalstrength for the soil nail support. Particularly in installations wherethe soil nail may be placed in a more horizontal location, withoutproviding some means to maintain uniform spacing between the inner andouter member, the inner member will have a tendency to lie against theouter member therefore minimizing the effectiveness of the inner member.

Referring to FIG. 19 in yet another embodiment of the present invention,in lieu of providing crimps to narrow the diameter of the outer memberan insert or spacer 230 is used to offset or space the inner member fromthe outer member.

In FIG. 19 the insert 230 is shown as being placed within the inner bore205 of the outer member 202. The insert includes an outer peripheralportion 232 that is placed in frictional engagement with the innersurface of the outer member, an inner concentric portion 234 with anopening 236 that receives the inner member 204, and a plurality ofradial supporting projections 238 that interconnect the inner concentricportion 234 with the outer peripheral portion 232. The radial supportingprojections 238 enable grout to pass through the spacer 230 when theouter member is being filled. The size of the opening 236 is adapted toreceive the inner member 204 and the inner member will maintain auniform spaced relationship with the interior surface of the outermember.

The insert 230 can be used at various locations along the length of theouter member to include intermediate between the proximal and distalends, as well as placed at the proximal and distal ends.

Referring to FIG. 20, a composite self-drilling soil nail 300 isillustrated in another embodiment. The soil nail includes a threadedouter member 302 and a threaded inner member 304 which is receivedthrough the bore or opening of the threaded outer member. The bore ofthe outer member may be smooth or may also be threaded to receive theinner member. A bearing plate 306 is placed over one end of the soilnail, and the bearing plate has a central opening which is large enoughto receive the outer member. The bearing plate is shaped and sized forholding the particular geological feature being stabilized. An outersecuring nut 308 is threaded over the outer tubular member 302 and istightened against the abutting surface of the bearing plate 306. Aninner securing nut 310 is then threaded over the threaded inner member,and tightly against the abutting surface of the outer securing nut 308.A self-drilling tip 312 is secured to a distal end of the soil nail 300.The soil nail may be extended in length by providing more than onesection or length of the outer member 302. Accordingly, two outermembers may be placed end to end and connected by a threaded outer tubecoupler 314.

In another aspect of the present invention, surface asperities may beformed on a soil nail by a galvanization process. The outer supportmember is dipped in a molten metal, such as zinc. Prior to dipping, thegalvanizer tank is stirred to mix the dross. Therefore, it is preferablethat none of the dross should be skimmed or removed from the galvanizertank. The molten metal along with the dross adheres to the surfaces ofthe member being dipped. Upon drying, the galvanized layer has a veryrough texture. This rough texture increases the pull-out capacity of thesoil nail, also increases the bond capability between the interiorsurface of the bore and grout or other cementious material placed withinthe outer member. Thus, the suspended dross particles which are normallyremoved from the molten material in a galvanization process provide avery useful purpose in creating a soil nail having an outer member withsurface asperities. Additionally, it is contemplated that the innermember can also be subjected to this type of galvanization process inorder to increase surface asperities on the inner member that alsoimproves bond between the grout in the bore of the outer member and theinner member.

FIG. 21 illustrates a plurality of soil nails 360 that are used torepair a roadway in which a slip plane P exists in the roadbed areabelow the road surface R. Without disrupting the slip plane, continualcracking of the roadway will occur as the slip plane continues to shiftover time. Therefore, numerous attempts to simply repair the roadsurface will be unsuccessful as the problem lies in the earth beneaththe road surface. As shown, a plurality of the soil nails 360 are use incombination and extend substantially perpendicular to the slip plane Pthereby stabilizing the soil on both sides of the slip plane andinterrupting the capability of the slip plane to naturally shift overtime.

Referring also to FIG. 22, the construction of each of the soil nails360 include the use of an outer member 362, and inner member 364 that isplaced within the outer member 362, in which grout, resin or othercementious material is used to hold the inner member 364 within theouter member 362. For the area excavated above the slip plane P, a wiremesh material 368 is placed. The mesh provides further support for thesoil nails, as well as to further disrupt the ability of the slip planeto shift. The mesh 368 is secured to each of the soil nails by, forexample, an epoxy-coated nut 370 that is tightened against thegalvanized plate 366. The galvanized plate 366 is also sized to providenecessary support to prevent shifting of the soil. Finally, the roadwayR may be repaired in which the soil nails are entirely located below theroadway R.

With the method and apparatus of the present invention, a subsurfacesupport is provided which can be emplaced with a minimum of effort. Inone advantage of the present invention, the subsurface support providesan alternative to other anchoring means because the outer tube providesprotection to the inner support member from corrosion or otherundesirable environmental factors. Depending upon the geologicalconditions, the outer tube can be emplaced with a launching device thatis adapted to account for varying geological formations. For example,ground formations with little rock allows emplacement of the outer tubewith a minimum of force while placement of the outer tube into an actualrock formation would require a greater force provided by the launchingmechanism. In any case, the particular launching device chosen may havethe capability of emplacing the outer tube to the appropriate depth andthrough various rock and soil conditions. In another advantage of thepresent invention, an improved soil nail is provided in a two-piececonstruction. This construction is cost effective yet provides at leastthe same performance as compared to a soil nail made of a single pieceof material. While surface asperities are illustrated with respect tothe embodiments shown in FIGS. 9-14, the other subsurface supports ofthe invention may also include such surface asperities to improve pullout capacities.

In some of the preferred embodiments, means is provided to maintain auniform spaced relationship between the inner member and the outermember to maximize the strengthening effect of the inner member for bothapplications in tension and compression. These means include crimpedfeatures formed directly on the outer member or the use of insertsplaced within the outer member.

The outer members may be placed in series to extend the length of thesupport in which a threaded coupling is used to join abutting outermembers. A self-drilling bit may be used for direct installation of theouter tube without having to conduct a separate drilling step.

While the method and the apparatus of the present invention have beenprovided in various preferred embodiments, it shall be understood thatvarious other changes and modifications may be made within the spiritand scope of the present invention.

1-9. (canceled)
 10. A method of improving the pull-out capacity andadhesion of a soil nail, said method comprising: providing a soil nailincluding an outer tubular member; providing a galvanizing tank having amolten metal therein; maintaining dross of the molten metal anddisbursing the dross by stirring the molten metals; dipping the outertubular member into the molten metal wherein upon cooling, said outertubular member has a rough surface comprising a layer of applied metaland dross particles.
 11. A method, as claimed in claim 10, furtherincluding: said dipping step further includes dipping an inner memberinto the molten metal so that said inner member has a rough surfacecomprising the layer of applied metal and dross particles; and placingthe inner member within the outer tubular member.
 12. A method ofinstalling a soil nail into an earthen ground, comprising: providing asoil nail including an outer tubular member; providing a galvanizingtank having a molten metal therein; maintaining dross of the moltenmetal and disbursing the dross by stirring the molten metals; dippingthe outer tubular member into the molten metal wherein upon cooling,said outer tubular member has a rough surface comprising a layer ofapplied metal and dross particles; taking the cooled soil nail andsecuring the soil nail to a launching device; launching the soil nailfrom the launching device wherein compressed gas within the launchingdevice forces the soil nail to be separated from the launching deviceand driven into the ground.
 13. A method, as claimed in claim 12,further including: said dipping step further includes dipping an innermember into the molten metal so that said inner member has a roughsurface comprising the layer of applied metal and dross particles;placing the inner member within the outer tubular member; and whereinsaid launching step further includes launching the soil nail comprisingthe outer tubular member and the inner member.